Connector of a type used with dry cell batteries and manufacturing method

Abstract

A connector of a type used with dry cell batteries comprises an insulating support having a snap fastener plug terminal and a snap fastener socket terminal on one surface thereof. The support has terminal supporting projections on its one surface and the terminals are stamped and formed sheet metal members. The terminals are partially inserted through the support so that the external contact portions of the terminals are against the terminal supporting projections and the internal or second contact portions of the terminals are on the reverse surface of the support. The connector can be used as a closure for the jacket of a 9-volt battery. A manufacturing method for the connector is also disclosed.

I claim: 
     
       1. A connector of the type comprising an insulating support having a snap fastener plug terminal and a snap fastener socket terminal on a first surface thereof, said snap fastener plug and socket terminals being dimensioned to be coupled to a complementary snap fastener socket terminal and a snap fastener plug terminal respectively on a similar connector, said connector being characterized in that: said support comprises a molded thermoplastic member having an integral plug terminal supporting portion and an integral socket terminal supporting portion on said first surface,   said plug terminal and said socket terminal each being a one-piece stamped and formed sheet metal member having first and second contact portions, each of said terminals being partially inserted through said support so that the first contact portion of each terminal is on said first surface of said support and said second contact portion is on a second surface of said support which is oppositely directed with respect to said first surface,   said first contact portion of said plug terminal being against, and supported by, said plug terminal supporting portion, said first contact portion of said socket terminal being against, and supported by, said socket terminal supporting portion.   
     
     
       2. A connector as set forth in claim 1, said plug terminal supporting portion and said socket terminal supporting portion each comprising a generally cylindrical projection on said first surface, said plug terminal supporting portion and said socket terminal supporting portion each having an external surface, said socket terminal supporting portion being hollow and having an internal surface, said first contact portion of said plug terminal being against the external surface of said plug terminal supporting portion, said first contact portion of said socket terminal being against the internal surface of said socket terminal supporting portion. 
     
     
       3. A connector as set forth in claim 2, each of said terminals being generally U-shaped having a web and sidewalls, said web of each terminal being said second contact portion, said sidewalls of each terminal being said first contact portion, said terminals being partially inserted through said support from said second surface to said first surface, said web portions of said terminals being against said second surface. 
     
     
       4. A connector as set forth in claim 3, said sidewalls of said terminals and said terminal supporting portions of said insulating support having free ends, said free ends of said sidewalls of said terminals being formed over said free ends of said terminal supporting portions. 
     
     
       5. A connector as set forth in claim 4, said support being a rectangular closure for one end of a tubular jacket for a dry cell battery. 
     
     
       6. A connector as set forth in either of claims 1 or 5, said connector being integral with a continuous strip of identical connectors, the insulating support of each connector being integral with the insulating support of adjacent connectors. 
     
     
       7. A connector as set forth in claim 1, each of said terminals being partially inserted through said support from said first surface to said second surface. 
     
     
       8. A connector as set forth in claim 7, said second contact portions of said terminal extending beyond said second surface of said support. 
     
     
       9. A connector as set forth in claim 8, said second contact portion of each of said terminals having a wire-receiving slot therein whereby wires can be inserted into the slots to contact the wires to the terminals. 
     
     
       10. A connector as set forth in claim 8, said second contact portions of said terminals comprising solder tabs. 
     
     
       11. A connector as set forth in either of claims 9 or 10, said connector being integral with a continuous strip of identical connectors, the insulating support of each connector being integral with the insulating support of adjacent connectors. 
     
     
       12. A dry cell battery of the type comprising a tubular jacket having at least one open end, at least one cell contained in said jacket, an insulating closure in said open end, said closure having an internal surface and an external surface, at least one terminal on said external surface, said terminal being connected to said cell, said battery being characterized in that: said closure is a molded thermoplastic member having terminal supporting portions on said external surface,   said terminal being a shaped sheet metal member having external contact portions and internal contact portions, said external contact portions being on said external surface of said closure and being supported on said terminal supporting portions, said internal contact portions being contained within said jacket and being adjacent to said internal surface of said closure,   said terminal being partially inserted through said closure from one side to the other side so that said external contact portions are on said external surface and said internal contact portions are adjacent to said internal surface, and   cell connecting means in said jacket serving to connect said internal contact portions to said cell.   
     
     
       13. A dry cell battery as set forth in claim 12, said terminal supporting portions comprising a generally cylindrical upstanding projection on said external surface of said closure, said external contact portions of said terminal being against surface portions of said projection. 
     
     
       14. A dry cell battery as set forth in claim 13, said projection being hollow, said external contact portions of said terminal being against the outside surface of said projection, said terminal being a plug terminal which is dimensioned to be mated with a complementary socket terminal. 
     
     
       15. A dry cell battery as set forth in claim 13, said projection being hollow, said external contact portions of said terminal being against the inside surface of said projection, said terminal being a socket terminal which is dimensioned to receive a complementary plug terminal. 
     
     
       16. A dry cell battery as set forth in claim 12, said closure having two terminal supporting portions on the external surface thereof. 
     
     
       17. A dry cell battery as set forth in claim 16, each of said terminal supporting portions comprising a hollow cylindrical projection on the external surface of said closure, one of said terminals having its external contact portions against the external surface of its associated projection and the other of said terminals having its external contact portions against the internal surface of its associated projection, said one terminal being a plug terminal and the other terminal being a socket terminal. 
     
     
       18. A dry cell battery as set forth in either of claims 12 or 17, said terminal being U-shaped and being inserted through said closure from the internal surface of said closure to the external surface. 
     
     
       19. A method of making a dry cell battery of the type comprising a tubular jacket having an open end, a flat platelike closure in said open end, said closure having a first surface which is the external surface of the closure and a second surface which is the internal surface of the closure, a plug type snap fastener terminal and a receptacle type snap fastener terminal on said first surface, said terminals extending through said closure to said second surface and being connected to a power source which is contained in the jacket, said terminal extending normally of said first surface, said method comprising the steps of: producing said closure as a thermoplastic molded part having integral terminal supporting portions extending from said first surface,   producing said terminals as sheet metal stamped and formed members, each having an external contact portion and an internal contact portion and with one of the portions having an edge and being capable of being inserted through said closure upon pushing the edge through the closure,   inserting said terminals through said closures so that the external contact portion of each terminal is against, and supported by, its associated terminal supporting projection and its internal contact portion is proximate to said second surface of said closure, and   assembling the power source and the closure to the jacket so that the power source is electrically connected to the internal contact portions of the terminals.   
     
     
       20. A method of making a dry cell battery as set forth in claim 19 in which said terminals are inserted through said closure from the second surface to the first surface. 
     
     
       21. A method as set forth in claim 20 in which each of said terminals is substantially channel-shaped having a web and sidewalls, the sidewalls of each terminal being the external contact portion and the web being the internal contact portion, the sidewalls of the terminals having free ends, each of said free ends having an edge thereon which is pushed through said closure. 
     
     
       22. A method of making a dry cell battery as set forth in claim 21 in which said closure is produced as a single closure in a continuous strip of closures and said terminals are produced as single terminals in continuous strips of terminals, said terminals being assembled to said closure by the steps of feeding said strip to an assembly zone, severing said terminals from said strip, moving said terminal towards, and inserting said terminals through said closure, and severing said closure from said strip of closures.